Staff Mechanical Design Engineer - Flight Hardware Lead

Castelion Corporation; Torrance (CA); On-site; USD 150,000 - 190,000; Full time

Job summary

Castelion is seeking a high-output Staff Mechanical Design Engineer with 8+ years of experience to own critical flight hardware from concept through flight. You will lead design, analysis, testing, and delivery, serving as a technical domain expert and mentor to the team.

You will develop expertise in mechanisms, structures, or avionics packaging, set high standards for design and manufacturability, and collaborate with technicians, suppliers, and test teams to drive hardware readiness and rapid

Qualifications

• Bachelor's degree in Mechanical Engineering or related field.
• 8+ years of professional mechanical engineering experience.
• Experience taking complex hardware from concept through design, analysis, manufacturing, integration, test, and operation.
• Deep expertise in mechanisms, structures, avionics packaging, or similar.
• Expert-level CAD and mechanical design skills, including GD&T, tolerancing, materials, and manufacturability.
• Strong understanding of structural mechanics, statics, vibration, and FEA.
• Experience designing high-performance hardware with constraints on mass, cost, schedule, reliability, and manufacturability.
• Strong hands-on problem-solving skills and experience working directly with hardware.

Responsibilities

• Own Flight Hardware: Lead the design, analysis, build, integration, and test of critical flight hardware from concept through flight.
• Technical Excellence: Serve as a technical authority in a mechanical domain such as mechanisms, structures, or avionics packaging. Establish and maintain high standards for design, analysis, manufacturability, and flight readiness.
• Structural Analysis: Perform and/or lead structural analysis using first-principles engineering, FEA, statics, vibration, and modal analysis.
• Rapid Development: Drive high-cadence design iterations, incorporating test results and lessons learned into rapid hardware improvements.
• Hands-On Engineering: Work directly with technicians, manufacturing, suppliers, and test teams to troubleshoot hardware and drive problems to closure.
• Engineering Leadership: Mentor engineers through design reviews, technical problem-solving, and hands-on coaching. Raise the technical capability and engineering standards of the broader team.
• Engineering Rigor: Improve CAD, analysis, documentation, hardware development, and design practices while maintaining speed and technical discipline.

Skills

CAD/Mechanical design

GD&T

FEA

Mechanisms/Structures

Problem-solving

Education

Bachelor's degree in Mechanical Engineering or related field

Tools

CAD software

FEA software

Job description

Castelion is seeking a high-output Staff Mechanical Design Engineer with 8+ years of experience to own critical flight hardware from concept through flight. You will lead design, analysis, testing, and delivery, serving as a technical domain expert and mentor to the team.

You will develop expertise in mechanisms, structures, or avionics packaging, set high standards for design and manufacturability, and collaborate with technicians, suppliers, and test teams to drive hardware readiness and rapid